Hf-bf3-h2o isomerization catalyst



Oct. 25, 1949. F. E. FREY 2,486,368

HF-BF5 -H 0 ISOMERIZATION CATALY'ST original Filed Nov. 25, 194:5'

OIL

SLUDGE HBZINVLNBdOSIBG HEATR HBZINVLOBOSIBG |soP ENTANE PEM-MEl SLUDGE HOLVNOILDVH :l

ISOBUTANE BD LVNOLLDVH NORMAL uolvgvdas RECYCLE v lNvENToR FREDEmcK E.FREY

#VM/UW M4( M,

ATTCRNEYS Patented Cet. 25, 1949'- HF-BFa-HzO ISOMERIZATION CATALYST Frederick E. Frey, Bartlesville, Okla., assignor to Phillips Petroleum Company, a corporation of Delaware Original application November 23, 1943, Serial No. 511,444. Divided and this application February 11, 1946, Serial No. 646,735

This invention relates to the reconstruction of hydrocarbons. In a specific embodiment it ret lates to the reconstruction of saturated hydrocarbons in the presence of a catalyst comprising a major proportion of concentrated hydrofluoric acid and a minor proportion of boron fluoride. This application is a divisional application of my copending application Serial No. 511,444, led November 23, 1943, now U. S. 2,461,541, which in turn is a continuation-impart of my copending application Serial No. 460,867, now U. S. 2,461,540, led on October 5, 1942, which in turn is a continuation-impart of my copending application Serial No. 426,627, filed January 13, 1942,'now Patent 2,403,649, issued July 9, 1946. This latter application is in turn a continuationin-part of my application Serial No. 323,443, filed March 11', 1940, now Patent 2,317,901, issued April 27, 1943.

The aforementioned earlier applications disclose that, in the presence of substantial proportions of hydroiluoric acid and under suitable conditions of time and temperature, saturated hydrocarbons are reconstructed to hydrocarbons of different carbon-skeleton arrangement. and different boiling point. Paraiiinic hydrocarbons, for example, undergo conversion to isomers and also undergo conversion to hydrocarbons of both lower and higher molecular weights and correspondingly lower and higher boiling temperatures. \I have found a marked improvement in the efficiency and utility of concentrated hydrouoric acid as a catalyst for reconstructing hydrocarbons is brought about by including with it a minor proportion of boron fluoride.

An object of this invention is to improve con-` centrated hydrofiuoric acid as a catalyst for reconstructing hydrocarbons.

Another object of this invention is to provide` an improved catalytic process for isomerizing normal butane to isobutane.

Another object of this invention is to produce isobutane, isopentane, and isohexanes from normal pentane.

Another object of this invention is to produce isobutane and isohexanes from isopentane.

A further object of my invention is to effect a catalytic conversion of hydrocarbons.

Another object is to obtain a hydrocarbon conversion of a drastic type, with fracture of the `carbon skeleton and with consumption of only low and economical amounts of BF: as well as Still another object of my invention is to reduce the formation of sludge in the reconstruction of hydrocarbons using hydrogen fluoride as the catalyst.

2 claims. (o1. 25a-'438) Other objects and advantages of this invention will become apparent, to one skilled in the art, from the accompanying disclosure and discussion.

The present invention comprises treating hydrocarbons, preferably saturated hydrocarbons such as the parailns and cycloparatllns, with concentrated hydrofiuoric acid, which contains, or which has had added to it, a minor proportion of boron fluoride toA produce other hydrocarbons. By various modifications of my invention I can convert parain hydrocarbons to other paramn hydrocarbons isomeric with the parafllns treated; I can convert parafiln hydrocarbons to other paraflin hydrocarbons having more and/or fewer carbon atoms per molecule; and I can convert cycloparafns to other cycloparailins having different alkyl groups and/or a different number of carbon atoms in the ring. In carrying out my invention it appears that two types of reaction occur. One of `these reactions is true isomerization as when' normal butane is converted to isobutane, normal pentane to isopentane, methylcyclopentane to cyclohexane and the like, and also the reverse of these reactions. The other reaction which appears to be involved is primarily one of disproportionation as when normal pentane is converted to more or less equimolar amounts of butanes and hexanes with the iso `compounds generally predominating. In many instances these two types of reactions take place concurrently with the formation of products which include isomers of the original hydrocarbons treated and hydrocarbons having fewer and greater numbers of carbon atoms per molecule.

However, in most cases the reaction conditions.

(l) 2C8Hu (I) 06H14 04H10 (pantanos) (hexanes) (butanes) (a) n-heptane L branched heptanes (b) n-butane S isobutane ln CHxCiHl @(cycloherane) v (methylcyclopentane) Although several other types of reaction probably also take place in the reconstruction process, the above-mentioned types appear to account for most of the effects which are produced. .The general term "reconstruction is used herein to denote the production of one or more of the above-mentioned eifects-aiid/or other advantageous effects which result from the practice of my invention.

The catalyst employed in the practice of my invention comprises a major proportion of hydrofluoric acid modified or activated by a minor proportion of boron triiiuoride. No nickel or other catalytic' agent is required, and in many cases the reactions may be carried out at normal atmospheric temperature or at a temperature only somewhat higher than atmospheric temperature. In its preferred form my catalyst comprises a homogeneous liquid solution of boron fluoride in a large excess of liquid hydrofiuoric acid. In determining the so-called K constants of solutions of boron triiiuoride in liquid anhydrous hydrouoric acid it has been determined that there appears to be primarily a true solution of boron triiiuoride in the liquid hydrofiuoric acid. However, an induction period has been observed which, in certain instances, has been eliminated by the addition of reactive hydrocarbons, such as olens. Also, complexes between hydrocarbons and the catalyst ingredients have been found in the catalyst phase after use. In a still further preferred modification of my invention I include in this catalytic mixture a small amount of water since, as will beshown hereinafter by data obtained in making comparative runs, thel A use of strictly anhydrous hydrouoric acid and a minor amount of boron triuoride as the catalyst is attended with the formation of an appreciable amount of organic sludge. This sludge does not make the use of an anhydrous catalyst impractical or uneconomical but, as can readily be appreciated, is undesirable. I have now found that when the catalyst is not strictly anhydrous, but contains a small amount of Water, there is a much smaller amount of sludge formed and at times the amount of sludge is practically negligible.

An understanding of various aspects of my invention may be aided by referring to the accompanying drawing and the following discussion thereof. The drawing is a schematic flow diagram showing one arrangement of apparatus which may be used in the practice of one embodiment of the invention. In order that the discussion may be sufficiently specific to be clear the embodiment discussed will be limited to the reconstruction of normal pentane, which will include both lsomerization to form isopentane and disproportionation to form butanes and hydrocarbons having more than five carbon atoms per molecule which will be primarily hexanes. However, by suitably controlling the reaction conditions, particularly by adding modifiers such as free hydrogen, cycloparaflins and the like, the reaction can be controlled to effect increased amounts of isomerization at the expense of disproportionation. As will be appreciated, the invention may also be applied to other saturated hydrocarbons as herein discussed.

Referring now to the drawing, normal pentane, preferably in the liquid phase, is introduced through inlet I IJ to reactor II. Concentrated hydroiuoric acid is introduced through inlet I2 and conduit 32, also preferably in the liquid phase, and a minor amount of boron triuoride is introduced through inlet I3 and passes through con- 4 duits I2 and 32 to reactor II. Although it is not definitely established that the reactions will not take place with both the hydrocarbons and catalyst in vapor phase, it is known to be definitely preferable to have at least the catalyst in liquid phase, and it is also preferable to have both the catalyst and the hydrocarbon material in liquid phase. The proportion of boron triiiuoride should be such as to be present to the extent of at least about 0.1 per cent by weight of the hydrofluoric acid. Although the amount of boron triuoride may be as much as about 20 to 30 per cent by weight of the hydrofiuoric acid, I have found that little benet is to be derived from having the amount greater than about 10 per cent by weight. In most instances satisfactory and eilicient operation is obtained when the amount of boron trifiuoride is between about 1 and about 5 per cent by weight. Such a composition is a very active catalyst, particularly for treating pentanes and heavier hydrocarbons at about atmospheric temperature, while at the same time the amount of boron triuoride present is sufficiently low that excessive costs for replacing and regenerating the catalyst are not incurred, and that excessive pressures are not necessary in order to keep a liquid phase operation, and further extensive corrosion of the usual materials for construction of the reaction vessels such as ordinary steels is not unduly high. Substantially more drastic reaction conditions are necessary in effecting the reconstruction of butane and successful operation is generally obtained only by using a somewhat higher proportion of boron triuoride together with somewhat higher temperatures and longer reaction times. In many instances the proportion of boron triiluoride which is used will be to some extent correlated with the other reaction conditions and in general a lower reaction temperature may be used with somewhat higher concentrations of boron triiluoride and also a shorter reaction time will be satisfactory with somewhat higher concentrations of boron triuoride.

As previously mentioned a small amount of water is also employed to obtain the most satisfactory operation. This water may be added directly to reactor II through conduit 8, or may be added at least in part to the hydrocarbon charge by means of conduit 9 which leads from conduit 8 to conduit I0. Although the necessary amount of water can be included in the hydrofluoric acid introduced through conduit I2, the other manner of operation is preferred. Often a satisfactory amount of Water can be maintained in the reaction system after the operation .has started by partially or completely saturating the liquid hydrocarbon material charged through conduit I0 with dissolved water. The concentration of water in the reactor should be at least about 0.05 per cent by Weight of the hydrofluoric acid-boron fluoride catalyst and generally need not exceed about 1.0 per cent by weight, although in some instances higher concentrations may be found to be desirable. However, the amount of water used should not exceed the molecular equivalent of boron triuoride present since it appears that the Water immediately disappears as such through the formation of a complex with the boron trifluoride, and an appreciable amount of free boron trifluoride must be present to effect the reconstruction reactions at a desirably rapid rate in the preferred temperature range. With added Water the amount of boron triuoride pres- 5 ent in excess of that molecularly equivalent to the water should be within the ranges hereinbefore discussed, namely at least about 0.1 per cent by weight and preferablyabout 1 to about 5 per cent by weight, or somewhat more in some instances. When the reaction is carried out in a long reaction zone of restricted cross-sectional area, as in a tube coil, it may be found desirable to add Water and/or boron trifluoride at various points along the length of the reaction zone. The relative proportions of catalyst and hydrocarbon are within a wide range not greatly critical. carbon to catalyst weight ratio in the range of about 0.1:1 to 3:1 or more, and preferably this ratio should be within the range of about 0.5:1 to 1.521. In any event it is desirable to operate under conditions of temperature, pressure and concentration such that an appreciable amount of a liquid hydrofiuoric acid phase is present in the reaction zone. The catalyst and the `hydrocarbon reactants should be brought into and maintained in intimate contact, and preferably such contact is eected by mechanical mixing resulting in substantial emulsication of the two phases. This may be done by means of a mixing pump, by passing the mixture at a high velocity through a series of bailies, by injecting the'hydrocarbon charge at a high velocity through a jet into a body of the reaction mixture, by recirculation, or the like as can be readily effected by one skilled in the art.

While the reaction temperature may be within a rather wide range as between about and about 400 F., satisfactory operation is generally obtained within a much narrower range, and suitably rapid reaction velocities have been secured at temperatures within the range of about 50 to about 250 F. With other reaction conditions constant the reaction rate is slower at low temperatures than at high temperatures and the rate of spending of the catalyst and the extent of secondary reaction and degradation of the product is greater at higher temperatures than `at lower temperatures. As previously mentioned, with other reaction conditions constant the rate of the reactions are somewhat greater with higher concentrations of boron triuoride than with lower concentrations, although in most instances satisfactorily rapid reaction rates are obtained when the concentration of free boron triuoride is not greater than about per cent by weight. The reconstruction of normal butane and also of normal hexane appears to require appreciably more drastic reaction conditions than those at which can be satisfactorily used when treating normal pentane.

With other reaction conditions constant the optimum reaction time varies in general more or less inversely with the reaction temperature. For temperatures within the above-mentioned preferred ranges a satisfactory reaction time will generally be found within thc range of about 5 to about 60 minutes. With 'ft-ry short times in reaction the conversion is relatively incomplete so that large amounts of unreacted material are made and in continuous operations there is an unnecessarily heavy load on subsequent separating and recycling equipment. If the reaction time is excessively long secondary reactions become involved to an undesirable extent and the life of the catalyst in terms of quantity of product per unit quantity of catalyst is excessively short. Satisfactory operations have been obtained with a correlation of the reaction condi- Good results are Aobtained using a hydro- 40 through outlet 2I.

tions to give as high as '70 to 90 per cent'conversion per pass in the reconstruction of nor'mal pentane, and as high as 60 to 80 per cent per pass for reconstructing isopentane. However, economical operations can be realized with appreciably lower conversions per y pass in many instances.

The reactions are not greatly affected by pressure, but, as previously mentioned, it is preferred l0 to have the catalyst and reactants in liquid phase in the reaction zone; a pressure suilicient to insure this, at the reaction temperature, is usually satisfactory as a reaction pressure.

The reaction mixture passes from reactor II 1s through conduit I4 to separator I5 wherein it is separated into two liquid phases as by gravitational settling. Cooling means not shown may also be employed to aid in the separation and the use of other devices such as centrifuges may also be included. The lighter or hydrocarbon phase,

which contains a small proportion of hydroiiuoric acid and boron triluoride dissolved in the mixture in conduit I4, is passed through conduit IB to fractionator I1. From fractionator I1 a mixture of low-boiling hydrocarbons containing small amounts of hydrogen fluoride and boron triiiuoride, is removed as an overhead product and may be recycled to separator I5 and/or may be passed through conduit 43 to reactor il.

In the event low-boiling hydrocarbons, such as system desired constituents. Hydrocarbon material, free from dissolved hydrofiuoric acid, is passed from the bottom of fractionator I1 through conduit I9 to deisobutanizer 20, wherefrom isobutanev is distilled overhead and is withdrawn Hydrocarbon material is passed from the bottom of deisobutanizer 20 through conduit 22 to deisopentanizer 23, wherefrom isopentane is distilled overhead and is withdrawn through outlet 24. At least a part of this material may be passed, if desired, back to reactor II from conduit 24 through conduits 4I and 21V. Hydrocarbon material from the bottom of deisopentanizer 23 is passed through conduit 25 to depentanizer 26, wherefrom normal pentane is distilled overhead and is recycled through conduit 2'!l to reactor I I. Isohexanes and other normally liquid hydrocarbons are passed from the bottom of depentanizer 2B through conduit 28 torerun column 29, wherefrom a major fraction suitable for blending in motor fuel isvdistilled overhead and is withdrawn through outlet 30. This fraction may be subjected to further` fractionation and purification, if desired. A

minor fraction of relatively high boiling material is withdrawn through outlet 3|. A fraction of intermediate boiling range may, if desired, be removed through conduit 42 and passed to conduit 21 and reactor II'.

A heavier catalyst phase is recovered from separator I5 and is recycled at least in part through conduit 32 to reactor II. Although with the use of' a small amount of water, as hereinbefore discussed, the amount of sludge forma- .70 tion is quite small, with prolonged continuous conduit 33 to purication equipment illustrated 7 by fractionator 34. From fractionator 34 a substantially purified hydroiiuoric acid is removed as an overhead product and is recycled through conduit 32 to reactor Il. This fraction will also contain the free boron trifluoride contained in Example I A series of test runs for reconstructing hydrocarbons were made in a closed 18liter steel reactor having a motor driven stirrer. The procedure was to charge predetermined quantities of anhydrous hydrofluoric acid, boron fluoride and hydrocarbon .material to the reactor, to adjust the reaction temperature by means of a heated water or oil bath surrounding the reactor, to stir the mixture for a suitable reaction time, to withdraw thereaction mixture, to separate the hydrocarbon products from the catalyst, and to determine the composition and properties gti the products. The following data were oba ned:

Test No 1 2 3 4 5 6 H droearbon charge n-pentane n-pentane n-pentane iso-pentane n-butane n butane B 3, Weightper cent of HF 2. 7 2. 9 3. 5 3. 8 2. 8 3. 3

Temperature, F 77-90 106-115 73-165 122-126 13S-144 151-174 Time, min 34 19 10 225 48 45 'Composition o( product, weight por cent:`

Propane 0 v 2.1 l. l 0 0 Isobutane.. 24.3 31.0 36.1 34. 2 4.8 10.8 N-butane. 1.2 3. 2 9.9 6. 7 95. 2 88.7 Isopentane. 19. l 20. 4 20. 9 20. 5 N-pentane. 29.8 15. 5 5. 8 3. 7 0 0. 5 Hexanes and heavier 25.6 29. 9 25. 2 33. 8

Total Conversion, weight per cent 70.2 84. 5 94. 2 79.5 4. 8 11.3 Composition ol hexanes and heavier, volume per cent:

12 12 2.; 46 as 31 23 25 18 8 11 10 Heavier 1l 14 l1 Pentian? free aviation fraction (336F. cut

nt Yield, volume per cent hexanes and heavier 97. 6 05. 2 97.3 97.9 Gravity, A. P. I 78.0 72.2 76.6 77.9 Octane No., A. S. T. M.:

Clear 71.8 71.8 68 0 73.8 l cc. TEL 85.8 85. 8 87. 7

heated and decomposed material then passes through conduit 38 to flash chamber 39, wherefrom hydrofluoric acid and boron fluoride are withdrawn overhead, and recycled through conduit 32 to reactor Il, and a high-boiling residue or sludge is withdrawn through outlet 40. Hydrogen fluoride may be introduced to conduit 36 and/or chamber 39 during the decomposition of the high-boiling catalyst complex and polymer to increase the amount of BFa released in molecular form.

It will be appreciated that the drawing is only diagrammatic, and that suitable specific equipment for the practice of any modification of my invention may be readily designated and designed by one skilled in the art. Although the description of the drawing has been limited primarily to a description and discussion of the reconstruction of normal pentane, the same principles which are involved may be readily applied to a reconstruction of other speciflc saturated hydrocarbons or hydrocarbon fractions, such as fractions secured from natural or straight-run gasolines, particularly the recycle of fractions of higher and/or lower boiling points, or ranges, than the hydrocarbon material in the net charge.

A few of the many aspects of my invention are illustrated by the following examples, which are illustrative but not necessarily limitative 'of the invention.

It is evident from this data that my invention is broadly applicable to the conversion of paraffin hydrocarbons to isomers and/or to hydrocarbons of higher and/or lower molecular weights. Recycling of undesired products may be employed to increase the ultimate yield of desired products.

Example II In another test run, normal hexane and concentrated hydrouoric acid to which has been added 5.2 weight per cent boron fluoride were shaken together in a closed steel pressure vessel for 40 minutes. The temperature was maintained at F. by an electric heater. The resulting hydrocarbon material was found to have the following composition:

The total conversion in this run was 58.5 per cent of the original normal hexane. It is evident that the principal reaction occurring in this test run was isomerization of normal hexane to isohexanes including neohexane and diisopropyl. It is further evident from this test run that my invention, in one of its modifications, may be applied to the production of high yields of neohexane and diisopropyl from less highly-branched hexanes. Such a modification comprises reconstructlng normal hexane and/or methylpentanes in the presence of concentrated hydroiluoric acid containing a minor proportion of boron fluoride, separating neohexane and/or diisopropyl from the resulting reconstructed hydrocarbon material, and recycling other hexanes and heavier hydrocarbons to the reconstructing step.

Example III In another test run, normal hexane was reconstructed under conditions similar to those of Example II except that the temperature was 260 Rand the time was 35 minutes. The resulting hydrocarbon was found to have the following composition:

The total conversion in this run was 96.1 per cent of the original normal hexane. The conditions for this run were more drastic than will usually be desired, since it is not usually desirable to produce such large proportions of propane. It is evident from this run, however, that at a somewhat lower temperature and/or a shorter reaction time high conversion of normal hexane to isobutane, isopentane, and isohexanes may be obtained. To produce neohexane drastic conversion conditions are especially effective, and recycling to the reaction zone of C4 and/or C5 hydrocarbons, and if desired hexanes and other paran fractions boiling somewhat above neohexane; these hydrocarbons result as sidel products under neohexane-producing conditions.

A fresh feed conversion stock primarily pentanes, as in Example I, or hexanes or a mixture is also suitable for neohexane production.

Example IV acid and/or boron uoride were added during the runs.

After each run, the reactor was inspected for the presence of sludge. The invention was practiced in runs 1 and 3 by saturating the ingoing normal pentane with water; data for runs 2 and 4,

inwhich water was excluded (the pentane was dried with Drierite) are included for comparison.

Run 1 2 3 4 Water (present or absent) present absent present absent Temperature, F 169 165 167 167 Pressure, p.s. i 350 500 350 350 Contact time (avg.) min. 25 30 11 Catalyst Composition,

weight per cent:

HF 96.9 96.9 97.4 96.9 BE; 3.1 3. 1 2.6 3. l Catalyst make-up, lb./

gal. nlpentane charged:

HF 0. 27 0.20 0.0 0. 17 BF; 0.06 0.05 0. 04 0.065 N -pentne reacted, per i cen 84 75. 5 68. 2 70 Yield, weight per cent of n-pentane reacted:

Propane 1. 8 3. 9 1. 9 l.. 2. 4 Isobutane 35. 5 33.0 33. 5 33. 7 N -butane 8. 8 7. 7 7. 9 6. 4 Osopentane 22. 5 27. 0 26. 2 28. 0 Branched hexanes 17. 4 16. 6 17. 3 17. 5 Hea er 14.0 11.8 13. 2 12. 0 Sludge formation. None Much Slight Much Example V Dimethylcyclopentane saturated `with water was agitated for 47 minutes at 185 F. and 275 p. s..i. with approximately twice its volume of hydrofluoric acid containing 1.5 to 1.6 mol per cent of boron fluoride. The hydrocarbon phase then had the following composition, in per cent by weight:

Propane and lighter 7.4 Isobutane 15.4 Isopentane 5.2 N-pentane 2.7

Hexanes 3.3 Dimethylcyclopentane 3.8 s Intermediate-cyclic cut 10.8A Methylcyclohexane 32.2 vHeavier 19.2

No apparent sludge formation occurred.

Example VI Temperature, F 1'76 Pressure, p. s. i 450 Contact time, min 14 Make-up BFs, lb./gal. n-hexane reacted 0.139

N-hexane reacted, wt. percent 35.2

Yield, wt. percent of n-hexane reacted:

Propane 1.7 Isobutane 22.4 N-butane 2.6 Isopentane 22.6 N-pentane 2.7 Branched hexanes 23.8 Heptanes and heavier 24.2

Sludge .formation None It will be appreciated that various modifications of my invention may be practiced without departing from the spirit of the disclosure and discussion or from the scope of the claims.

Comparison of the results of the batch run in Example II with those oi' the continuous run of Example VI indicates that formation of relatively iight products in the batch run was suppressed by hydrogen liberated by corrosion oi the steel pressure vessel.

I claim:

1. A catalyst consisting essentially of the product resulting from admixing liquid hydrogen fiuoride, between about 0.1 and about 10 per cent by weight of boron trluoride in excess of that molecularly equivalent to the water present, and water in an amount between about 0.05 and about 1.0 per cent by weight and less than that molecularly equivalent to the boron triiiuoride present.

2. A liquid composition of matter consisting essentially of a product resulting from admixing liquid hydrogen fluoride, boron uoride in excess of that molecularly equivalent to the water present in an amount between about 0.1 and about 5 per cent by weight of the total oi' hydrogen fluoride. water and boron trifiuoride, and water in an amount between about 0.05 and 1 per cent by weight and less than that molecularly equivalent to the boron triuoride present.

FREDERICK E. FREY.

REFERENCES CITED The following references are of record in the tile of this patent:

UNITED STATES PA'IEN'rs Number Name Date 1,933,434 Hoffman et al Oct. 31, 1933 2,283,142 Ipatieii' et al May 12, 1942 2,296,370 Slotterbeck Sept. 22, 1942 2,363,116 Bruner Nov. 21, 1944 

